A Method for Fabricating and Installing Porcelain Enamel Kitchen Countertops

ABSTRACT

A method for providing a countertop with a porcelain enamel surface. A metal substrate is provided with a series of cut lines. The metal substrate is formed to fit a countertop frame. A coating of porcelain enamel is applied to the surface of the metal substrate. The porcelain enamel is fused to the sheet metal through a firing process which preferably reaches between 1380 degrees Fahrenheit and 1560 degrees Fahrenheit. The metal substrate is installed over the countertop frame.

CROSS-REFERENCES TO RELATED APPLICATIONS

Not Applicable

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

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MICROFICHE APPENDIX

Not Applicable

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to the field of fabricating and installing porcelain enamel countertops. More specifically, the present invention relates to methods for fabricating single-unit countertops consisting of porcelain enamel fused to a metal substrate and installing same for use as a kitchen countertop.

2. Description of the Related Art

Porcelain enamel, or vitreous enamel, is a non-porous, glassy composition fused to a metal substrate by firing. For decades, porcelain enamel has been used in a variety of applications, such as tools, laundry appliances, bathtubs, and toilets. Due to its color permanence, resistance to abrasion and weathering, and resistance to odor and bacteria, porcelain enamel can also be found in the kitchen, where it is commonly used in cookware, flatware, and sinks.

Nevertheless, even though the kitchen sink might be made of porcelain enamel, the kitchen countertop in which it is installed is often made of other material, such as stone, cement, wood, or stainless steel. More recently, however, in recognition of the beneficial properties of porcelain enamel, designers and home-owners have begun to employ porcelain enamel in the kitchen countertop itself.

The current method of installing a porcelain kitchen countertop involves the use of pre-fabricated porcelain tiles which are bonded to a base surface or to the pre-existing countertop. The problem with this method is that it can be time consuming and extremely messy, as each tile needs to be individually placed and adhered to the base surface, and the porcelain tiles can crack or chip when being cut to fit around fixtures or sink openings. Additionally, because the countertop is comprised of several adjacent tiles, each joint'must be sealed with a caulking or molding. Not only do these joints interrupt the surface of the countertop, but the caulking itself can retain bacteria and mold, can be difficult to clean, and can damaged easily.

Therefore, what is needed is a method of fabricating and installing a porcelain enamel kitchen countertop that creates a smooth countertop surface without requiring the porcelain enamel to be cut or shaped and that eliminates or significantly reduces the need for caulking. The present invention achieves these Objectives, as well as others, which are explained in the following description.

BRIEF SUMMARY OF THE INVENTION

The method of fabricating and installing porcelain enamel kitchen countertops generally comprises the steps of providing a metal substrate with a series of cut lines, cutting the metal substrate to fit the dimensions of the countertop frame, applying a porcelain enamel coating to the metal substrate, firing the porcelain enamel coating at a temperature above 800° Fahrenheit, and installing the porcelain enameled metal countertop to the area to be covered.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a flowchart outlining the basic steps of the preferred arrangement of the present invention.

FIG. 2 is a perspective view, showing kitchen cabinetry to be covered using the present invention.

FIG. 3 is a perspective view, showing the metal substrate after it has been measured and marked for cutting.

FIG. 4 is a perspective view, showing the formed metal substrate after it has been cut and formed.

FIG. 5 is a perspective view, showing the formed metal substrate receiving a porcelain enamel coating.

FIG. 6 is a perspective view, showing the porcelain coated formed metal substrate being prepared for firing operations.

FIG. 7 is a perspective view, showing the porcelain enamel countertop being installed onto kitchen cabinetry.

FIG. 8 is a perspective view, showing the completed porcelain enamel countertop after fabrication and installation using the preferred arrangement of the present invention.

FIG. 9 is a perspective view, showing L-shaped kitchen cabinetry to be covered using an alternate arrangement of the present invention.

FIG. 10 is a perspective view, showing the metal substrate after it has been measured and marked for cutting to fit the measurements of L-shaped kitchen cabinetry.

FIG. 11 is a perspective view, showing an alternate arrangement of the present methodology to accommodate L-shaped kitchen cabinetry.

FIG. 12 is a perspective view, showing the installed porcelain enamel countertop with a backsplash using an alternate arrangement of the present methodology to fit L-shaped cabinetry.

FIG. 13 is a perspective view, showing an alternate arrangement of the present methodology in which a porcelain enamel countertop is installed on a pre-existing base countertop.

REFERENCE NUMERALS IN THE DRAWINGS

10 kitchen cabinetry 12 countertop frame 16 sink area 18 sink basin 20 metal substrate 22 cut lines 24 saw 26 formed metal substrate 28 sink opening 30 spray gun 32 top surface 34 edges 36 porcelain enamel coating 38 porcelain enamel coated substrate 40 kiln 42 bottom surface of metal substrate 44 porcelain enamel countertop 46 adhesive 48 first member 50 second member 52 tongue 54 groove 56 abutting edge 58 backsplash 60 bend lines 62 pre-existing base 64 base edges 66 countertop lips

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 is a flowchart showing the general steps that comprise the present invention. The preferred arrangement of this method for fabricating and installing porcelain enamel kitchen countertops generally comprises following steps: (1) providing kitchen cabinetry to be covered by a countertop; (2) providing a metal substrate suitable for fusion with a porcelain enamel coating; (3) measuring and forming the metal substrate to fit the dimensions of the kitchen cabinetry to be covered; (4) providing a porcelain enamel coating; (5) applying the porcelain enamel coating to the formed metal substrate; (6) firing, the porcelain coating to fuse with the metal substrate; and (7) installing the porcelain enamel countertop onto kitchen cabinetry with adhesive.

FIG. 2 is an example of one type of kitchen cabinetry 10 to be covered by a countertop as provided in step (1) of the present methodology. Such kitchen cabinetry 10 generally has an open countertop frame 12 to be covered by a countertop which has a series of measurements (or dimensions), and sink area 16 where sink basin 18 would generally be installed. In the preferred embodiment, kitchen cabinetry 10 as shown in FIG. 2 is attached to wall (not shown); however, the present methodology can be used to'cover various configurations of cabinetry, such as free-standing cabinetry, like an island, or L-shaped configurations, as will be discussed below. Once the layout of the kitchen cabinetry 10 to be covered is known, measurements of the dimensions of cabinetry frame 12 must be taken, including the length and width of sink basin 18 to be installed in sink area 16, and taking into account whether it is desired that the countertop be flush with or protrude out over countertop frame 12.

Step (2) of the present methodology provides for metal substrate 20, as shown in FIG. 3. In the preferred arrangement of the present invention, metal substrate 20 is comprised of 11 gauge cold rolled steel plate having a thickness of ⅛ inch. However, the metal substrate can be comprised of any cold rolled metal capable of bonding with porcelain enamel coating, which has formability, resistance to sagging, and high strength during firing, such as aluminum. It can also be comprised of a specially treated sheet metal, for example a vitreous enamel sheet manufactured by U.S. STEEL® (a U.S. registered trademark of the United States Steel Corporation, a Delaware corporation with its principal place of address in Pittsburgh, Pa.) that is specially treated to optimize fusion with porcelain enamel, or a metal with a reduced carbon content enabling the substrate to fuse with the porcelain enamel in a single coat. While the preferred arrangement of the present methodology generally comprises a single sheet of metal plate, if a thickness of greater than ⅛ inch is desired, two plates can be welded together, prior to coating, to create the desired thickness. The subsequent application of porcelain enamel coating to the welded plates, as discussed below in Step (5), will cover the seams such that the welded plates will appear to be one single sheet.

After selecting the material to be used as metal substrate 20 according to the above criteria, Step (3) comprises measuring and forming metal substrate 20 according to the measurements of countertop frame 12 taken in Step (1). The illustration in FIG. 3 shows a long piece of metal substrate 20 after it has been prepared to be cut by bandsaw 24. In FIG. 3, a large piece of metal substrate 20 has been marked with cut lines 22 to conform the length of metal substrate 20 to the measurements of countertop frame 12. It has also been marked with cut lines 22 to provide the opening for sink area in which sink basin (shown as 16 and 18, respectively in FIG. 2) will sit. Additional cut lines can be added if more cuts are needed in order to conform with the shape of metal substrate 20 to an alternate arrangement of kitchen cabinetry, such as L-shaped cabinetry as illustrated in FIG. 10.

Returning to FIG. 3, once all cut lines 22 have been marked, the required cuts are made using bandsaw 24. The preferred arrangement of the present methodology uses a bandsaw, which has been fitted with a metal cutting blade, to make the necessary cuts. However, cutting operations can be accomplished with any tool capable of cutting the material chosen to comprise metal substrate 20, such as power sheet shears, hand-held cutting shears, laser cutters, tin snips, punches, jig-saws, or CNC (computer numerically controlled) lasers. The resulting formed metal substrate 26, complete with sink opening 28, is illustrated in FIG. 4. The shape and desired openings can be modified according to the specifications of the countertop.

Step (4) of the present methodology provides a porcelain enamel coating 36, as seen in FIG. 5. In the preferred methodology, two coats of porcelain enamel coating 36 will be selected. First, a base coat must be selected. This base coat should contain metal oxides to facilitate fusion with formed metal substrate 26: Second, a cover coat should be selected, which can be white or colored according to preference. The thickness of the resulting porcelain enamel must also be selected to meet the desires of the designer or owner. In the present methodology, a thickness of 62.5 mils (or 1/16 inch) is preferred when applied to ⅛ inch steel plate. However, lighter coatings can be utilized provided that the metal substrate is thick enough to be self-supporting. For example, a thickness of 5 mils will be flexible enough to bend, while a thickness of 10 mils creates sturdier enamel. Additionally, coatings of 15 mils or more should only be used on heavy gauge steel or plate, as anything thicker will result in warping of the metal substrate if applied to thinner sheet metal.

Once the type of porcelain enamel coating 36 has been selected, Step (5) comprises applying porcelain enamel coating 36 to formed metal substrate 26, as shown in FIG. 5. First, formed metal substrate 26 must be degreased using a mild alkaline solution prior to coating. Once formed metal substrate 26 has been degreased, the base coat of porcelain enamel coating 36 is applied to top surface 32 and edges 34 of formed metal substrate 26 using spray, gun 30, followed by the cover coating applied in the same manner. Bottom surface of metal substrate 42, which can be seen in FIG. 7, is left uncoated.

Returning to FIG. 5, in the preferred arrangement of the present methodology, porcelain enamel coating 36 is in an electrostatic form, which can be applied using spray gun 30. However, a wet suspension of porcelain enamel coating (not shown) can also be used, which would be applied by dipping formed metal substrate into the wet porcelain enamel coating.

Once the porcelain enamel coating 36 has been applied, Step (6) provides for firing the porcelain enamel coated substrate 38 in a kiln 40, as illustrated in FIG. 6. Firing is accomplished by heating porcelain enamel coated substrate 38 in kiln 40 at a temperature above 800° F., and generally between 1380° F. and 1560° F. In the preferred arrangement of the present methodology, the electrostatic base coat and cover coat of porcelain enamel coating 36 can be fired at the same time. However, if using a wet suspension that requires a two-coat method, after firing the base coat, the cover coat can be applied as detailed in Step (5) and then fired in the same manner.

Once firing is complete, Step (7) provides for installation of the completed porcelain enamel countertop 44, as shown in FIG. 7. First, bottom surface of metal substrate 42, which has been left uncoated, and countertop frame 12 are covered with adhesive 46, preferably an epoxy capable of bonding metal to wood. Porcelain enamel countertop 44 is then placed on top of countertop frame 12 of kitchen cabinetry 10, such that bottom surface of metal substrate 42 is affixed to countertop frame 12. Clamps (not shown) can be used to hold porcelain enamel countertop 44 in place until adhesive 46 is completely dry. FIG. 8 shows the finished porcelain enamel countertop 44 as it might look after being fully installed onto kitchen cabinetry 10.

While the preferred arrangement of the present methodology comprises a rectangular arrangement of kitchen cabinetry 10, L-shaped kitchen cabinetry 10, as shown in FIG. 9, can also be accommodated using the present methodology. To fabricate a countertop for such an arrangement of kitchen cabinetry 10, the preferred arrangement of the present method comprises making additional cuts in Step (3), as discussed above and illustrated by the cut lines 22 shown in FIG. 10. However, if metal substrate 20 cannot cover the entire area, or a large enough kiln is not available for firing a single-unit countertop, FIG. 11 shows an alternate arrangement of the present methodology which can accommodate L-shaped kitchen cabinetry 10.

In this alternate arrangement, as shown in FIG. 11, during Step (3), first member 48, and second member 50 are cut, which will be adjoined to form metal substrate 26 by either adhering abutting edges 56 together with adhesive and filling the joint with caulking, which is then sealed, or by implementing a tongue and groove system. To implement the tongue and groove system, a router with a metal cutting blade (not shown) or any known method of cutting metal, is used to create groove 54 in abutting edge 56 of first member 48, and a complementary tongue 52 on abutting edge 56 second member. In Step (5), tongue 52 and groove 54 are covered during the porcelain enamel coating processed so that they remain uncoated. Then, in Step (7), tongue 52 and groove 54 are covered in metal bonding adhesive and tongue 52 is inserted or slid into groove 54 prior to being affixed to countertop frame 12. FIG. 12 shows the installed porcelain enamel countertop 44, comprised of first member 48 and second member 50, for L-shaped kitchen cabinetry 10 using this alternate arrangement of the present methodology.

In an alternate arrangement of the present methodology further comprises backsplash 58, as shown in FIG. 12. To fabricate backsplash 58, metal substrate 20 is bent along bend line 60, as shown in FIG. 10. Methods for bending metal plate are known and will not be discussed here, but any known tools or machines for bending metal plate, such as a break press, roll form, hammer, or punch and die press can be used to create a 90 degree upward bend in metal substrate 20 along bend line 60 to form backsplash 58. However, if metal substrate 20 is too small to accommodate the extra material needed to create a contiguous backsplash 58, bend line 60 can be converted to a cut line and backsplash 58 can be affixed to first member 48 using the same methods employed in affixing first member 48 to second member 50.

FIG. 13 shows an alternate arrangement of the present methodology in which porcelain enamel countertop 44 is installed over top of pre-existing base 62. Although the preferred arrangement of the present methodology generally comprises installing porcelain enamel countertop 44 to countertop frame 12, as shown in FIG. 7, some designers or owners might want to install porcelain enamel countertop 44 directly over top of pre-existing base 62, which could be comprised of a pre-existing countertop that has already been installed, or pre-fabricated plywood. In this alternate arrangement, Step (1) would consist of measuring pre-existing base 62, including the length of base edges 64. Step (2) would remain the same, but additional cuts and bends would be necessary in Step (3) to form metal substrate 20 to fit overtop pre-existing base 62. Such methods of forming metal substrate are known and will not be described in depth here other than to detail that the resulting formed metal substrate 26 would comprise countertop lips 66 that would protrude over and cover base edges 64. Steps (5), (6), and (7) would then be followed as described above, except that in Step (7) adhesive 46 would also be applied to base edges 64 and countertop lips 66 as porcelain enamel countertop 44 would be fitted overtop of pre-existing base 62, as illustrated in FIG. 13. 

Having described my invention, I claim:
 1. A method for making a porcelain-enameled countertop comprising the steps of: a. providing a countertop frame having a series of measurements; b. providing a metal substrate, having a surface; c. cutting said metal substrate to meet said series of measurements of said countertop; d. providing a coating of porcelain enamel applied to said surface of said metal substrate; e. heating said sheet metal to a fusing temperature forming said porcelain-enameled countertop; and f. installing said porcelain-enameled countertop on said countertop frame.
 2. The method for making a porcelain-enameled countertop as recited in claim 1, wherein said step of cutting said metal substrate to meet said series of measurements of said countertop further comprises a step of bending said metal substrate to form an integral backsplash.
 3. The method for making a porcelain-enameled countertop as recited in claim 1, wherein said fusing temperature is above 800 degrees Fahrenheit.
 4. The method of making a porcelain-enameled countertop as recited in claim 1, wherein said fusing temperature is between 1380° F. and 1560° F.
 5. The method of making a porcelain enamel countertop as recited in claim 1, wherein said step of providing a coating of porcelain enamel applied to said surface of said metal substrate further comprises spraying said porcelain enamel in an electrostatic form on said surface of said metal substrate.
 6. The method of making a porcelain enamel countertop as recited in claim 1, wherein said step of providing a coating of porcelain enamel applied to said surface of said metal substrate further comprises dipping said metal substrate into said porcelain enamel.
 7. A method for making a porcelain-enameled countertop comprising the steps of: a. providing a countertop frame; b. providing a metal substrate, having a surface and a series of cut lines; c. forming said metal substrate to fit said countertop frame; d. providing a coating of porcelain enamel applied to said surface of said metal substrate; e. fusing said porcelain enamel to said metal substrate by heating said porcelain-enamel and said metal substrate to a temperature of above 800° F. to form said porcelain-enameled countertop; and f. installing said porcelain-enameled countertop on said countertop frame.
 8. The method of making a porcelain-enameled countertop as recited in claim 7, wherein said step of forming said metal substrate to fit said countertop frame comprises cutting said metal substrate along said series of cut lines.
 9. The method of making a porcelain-enameled countertop as recited in claim 8, wherein said step of forming said metal substrate to fit said countertop frame comprises bending said metal substrate to form an overhanging front lip.
 10. The method of making a porcelain-enameled countertop as recited in claim 8, wherein said step of forming said metal substrate to fit said countertop frame comprises bending said metal substrate to form an integral backsplash.
 11. The method of making a porcelain-enameled countertop as recited in claim 8, wherein said fusing temperature is between 1380° F. and 1560° F.
 12. The method of making a porcelain enamel countertop as recited in claim 7, wherein said step of providing a coating of porcelain enamel applied to said surface of said metal substrate further comprises spraying said porcelain enamel in an electrostatic form on said surface of said metal substrate.
 13. The method of making a porcelain enamel countertop as recited in claim 7, wherein said step of providing a coating of porcelain enamel applied to said surface of said metal substrate further comprises dipping said metal substrate into said porcelain enamel.
 14. A method for making a porcelain-enameled countertop comprising the steps of: a. providing a countertop having a surface; b. providing at least two pieces of a metal substrate having a surface and a series of cut lines; c. cutting said metal substrate into a series of pieces along said series of cut lines; d. providing a coating of porcelain enamel applied to said surface of said series of pieces of said metal substrate; e. fusing said porcelain enamel to said metal substrate by heating said porcelain enamel and said metal substrate to a temperature of above 800° F.; f. fitting said series of pieces of said metal substrate together; and g. installing said porcelain-enameled countertop on said countertop frame.
 15. The method of making a porcelain enamel countertop as recited in claim 14, wherein said step of cutting said metal substrate into a series of pieces along said series of cut lines further comprises cutting a tongue and groove joint such that said series of pieces of said metal substrate can be fitted together.
 16. The method of making a porcelain-enameled countertop as recited in claim 14, wherein said fusing temperature is between 1380° F. and 1560° F.
 17. The method of making a porcelain enamel countertop as recited in claim 14, wherein said step of providing a coating of porcelain enamel applied to said surface of said metal substrate further comprises spraying said porcelain enamel in an electrostatic form on said surface of said metal substrate.
 18. The method of making a porcelain enamel countertop as recited in claim 14, wherein said step of providing a coating of porcelain enamel applied to said surface of said metal substrate further comprises dipping said metal substrate into said porcelain enamel. 